Oil Purification Systems, Inc. Purification Systems, Inc. Installation Instructions for Peterbilt Trucks Equipped with the Caterpillar C-13 Engine Document Part Number l-002

Oil Purification Systems, Inc.

Installation Instructions for

Peterbilt Trucks

Equipped with the

Caterpillar C-13 Engine

Document Part Number l-002

Document Edition Number 2.0

Edition Release Date November 2006

Copyright © 2006 Page 1

Table of Contents

Table of Contents Safety Precautions ........................................................................................................................2

General Precautions......................................................................................................................2

Notes for all Hose Connections:....................................................................................................2

Before Installing This System........................................................................................................2

Technical Support ....................................................................................................................... 2

Section 1 – Mounting the Evaporator ...........................................................................................3

Section 2 – Mounting the Filter..................................................................................................... 6

Section 3 – Supply and Return Line Hoses ................................................................................. 7

Hose Specifications ............................................................................................................ 7

Accessing the Supply Line Port .......................................................................................... 7

Connecting the Filter to the Evaporator .............................................................................. 8

Accessing the Return Line Port .......................................................................................... 9

Section 4 – Adjusting the Metering Valve................................................................................... 11

Checking and Adjusting the Flow Rate ............................................................................ 11

Section 5 – Electrical Connections ............................................................................................ 13

Connect the Power Source to the Evaporator .................................................................. 13

Apply Power to the Circuit ................................................................................................ 15

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Copyright Notice:

Copyright © 2006 Oil Purification Systems, Inc. All Rights Reserved. OPS-1 is a trademark of Oil Purification Systems, Inc. OPS-1 Patented 6,287,455. Patents Pending in the United States and other countries. Other trademarks and trade names that may be used in this document to refer to either entities claiming the marks and names or their products, OPS disclaims any proprietary interest in trademarks and trade names; such marks and names are owned by their respective holders.

Page 2 Copyright © 2006

Before You Begin

Safety Precautions

• Before beginning work, ensure the engine has sufficiently cooled to prevent burn injuries.

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General Precautions • Ensure the voltage of the system being installed matches that of the truck.

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Notes for all Hose Connections: • Use a heat gun or soak the hose ends in hot water to expand them to ease

assembling hoses over barbed fittings. Be sure to shake off any water from the hoses.

• Apply light oil such as silicon spray or WD40 inside the hose end to ease the assembly of the adaptor into the hose end. DO NOT use grease or engine oil for this purpose.

• Slide a ½” hose over each ¼” hose at those places where the hose comes close to moving or vibrating parts. This is to protect the ¼” hose from abrasion. Also add the ½” hose to the parts of the hose that bend. This will help the ¼” hose hold its shape and prevent crimping.

• Route all hoses away from extremely hot components, such as exhaust pipes and the turbos.

• Route all hoses away from moving parts, such as the radiator fan.

• Use ties to secure the hoses in place.

• Ensure the hose is the proper length before sliding them over the barbed hose fittings, as hoses must be cut to be removed from the fittings.

• Leave a slight amount of slack in the hose to allow for engine vibration.

• Use teflon tape on all NTP threads (used on the hose adaptors). _____________________________________________________________________

Before Installing This System

It is recommended that you perform an oil change on the vehicle before installing this system.

• Be sure to handle used oil in compliance will all applicable laws. This will usually include making provisions for recycling.

• Always wear oil resistant gloves when handling used oil.

_____________________________________________________________________ Technical Support ...........................................................Call Toll Free (866) OILPURE


Installation

Section 1 – Mounting the Evaporator

1. Near the center of the vehicle, remove the nuts that hold the horn bracket and windshield wiper motor to the firewall.

2. Replace the bolts that hold the horn bracket and wiper motor in place with 1-1/4” long ¼-20 bolts (to accommodate the added thickness of the evaporator mounting bracket).

3. On the passenger side of the vehicle, remove the two right side nuts (of the four total) that hold the hood stay in place.

4. Attach the evaporator to the supplied bracket. Insert the supplied bolts in from back of the bracket and use nuts on the front to attach the evaporator.

5. Mount the Evaporator bracket to the firewall. Near the center of the vehicle, position the bracket over the two bolts that hold the left side of the horn bracket in place. The horn bracket goes over the evaporator bracket and the evaporator bracket goes over the wiper motor bracket.

Figure 1 – The Horn Bracket Bolts

Remove thesetwo bolts to

mount theEvaporator

Bracket

Replace themwith 1-1/4” long

bolts.

This bracket remains in place.

Evaporator Bracket goes over thisand under the horn brackets.


Installation

6. On the passenger side of the vehicle, position the bracket over the two hood stay bolts.

Figure 2 – The Passenger Side Hood Stay

7. Use the original hood stay nuts to tighten the bracket in place. See Figures 3 and 4.

Figure 3 – Attaching the Passenger Side of the Evaporator Mounting Bracket

Remove these nuts from the Passenger side hood stay bracket and fit the Evaporator bracket over the hood stay bracket.


Installation

Figure 4 – Attaching the Driver Side of the Evaporator Mounting Bracket


Installation

Section 2 – Mounting the Filter The Filter mounts to the passenger side of the frame, about ½ way between the turbo halves.

IMPORTANT NOTE: Before drilling into the frame, check inside the frame rail for hoses or wiring that may be routed there. If hoses or wiring are present, move them out of the way or select a different location on which to mount the filter.

1. Drill two 5/16” holes in the frame, about 2” from the top, using the filter bracket as a template. See Figure 5.

Figure 5 – Mounting the Filter

2. Bolt the filter to the frame, using the supplied nuts, bolts and lock washers.

Filter Return Side Sends Pressurized Oil to the Evaporator

Filter Supply Side

Receives Pressurized Oil

From the Engine

SamplingPort


Installation

Section 3 –Supply and Return Line Hoses Hose Specifications

• ¼” hose, use Parker 836 high temperature, push lock hose, or the equivalent.

• ½” hose, use Parker 801 general purpose, push lock hose, or the equivalent.

Accessing the Supply Line Port:

On the passenger side of the engine, inside the frame rail, below the top of the frame, there is a plug that you will replace with a hose fitting to act as the pressurized oil supply to the filter.

1. Locate the plug. See Figure 6.

Figure 6 – The Oil Supply Line Plug

2. Remove the plug and replace it with the supplied adapter.

3. Measure the distance from this fitting to the supply side of the filter. Run the tape measure along the same route you will use for this hose. Add 1.5 – 2.0 inches to allow for engine vibration.

4. Cut the hose to length.

5. Slide the ¼” hose over the supplied ¼” barbed hose fitting.

6. Screw the hose fitting into the adapter already attached to the engine.

7. Slide the other end of the hose to the hose fitting that will go into the filter.

8. Attach the second hose fitting into the supply side of the filter.


Installation

Connecting the Filter to the Evaporator

1. Measure the distance from the return port on the filter to the supply port on the evaporator. Run the tape measure along the same route that the hose will follow. Add 1.5 to 2” slack to allow for engine vibration. See Figure 7 for typical routing.

Figure 7 – Routing the Hoses

2. Insert the hose fittings into each end of the hose.

3. Attach one fitting into the return side of the filter and the other to the supply side of the evaporator.


Installation

Accessing the return line port

The gravity fed return line attaches the return side of the evaporator to a port located on the top of the oil pan near the front of the passenger side of the engine. See the circled part of Figure 8.

1. Locate the port. See Figure 8.

Figure 8 – Locating the Port on the Oil Pan

2. Measure the distance from this flange to the return port on the evaporator. Run the tape measure along the same route you will use for this hose. Add 1.5 – 2.0 inches to accommodate engine vibration.

3. Cut the hose to length.

4. Remove the hose adapter from the engine.

5. Slide the ½” hose end over the hose fitting that will go into the oil pan.

6. Reattach the adapter to the engine. Remember to use teflon thread tape on the NTP threads which go into the oil pan.

7. Attach the fitting that will go into the return side of the evaporator into the other end of the hose.


Installation8. Route the second end of the hose next to the return side of the evaporator, and attach it

to the evaporator. See Figure 9.

Figure 9 – Location of Evaporator Supply and Return Ports

As this connection is gravity fed, you must follow these guidelines:

• The hose must slope downward.

• Do not allow any kinks or sharp bends in this hose.

• Follow the rules applicable to all hoses.

EvaporatorSupply Port

ReceivesPressurized Oil

From Filter

EvaporatorReturn Port

Gravity ReturnsOil to Engine

Evaporator Vent Hose


Installation

Section 4 – Adjusting the Metering Valve Checking and Adjusting the Flow Rate:

1. Open the Oil Shut-off Valve on the Filter. See Figure 10.

Figure 10 – Location of Shut-off Valve on the Filter

2. Start the engine and allow it to warm up to normal operating temperature. Set the engine speed to about 2,000 RPMs.

3. Check for leaks. If there are any, shut off the engine, repair the leaks, and restart the engine.

4. Close the Oil Shut-off Valve on the Filter.

Oil Shut-off Valve


Installation

Figure 11 – Location of Vapor Escape Valve

5. Close the metering valve and remove it from the Evaporator.

6. Open the Oil Shut-off Valve on the Filter.

7. With an oil catch pan under the metering valve, open the metering valve all the way for several seconds and allow the full oil flow to flush out the oil lines.

8, Close the metering valve all the way.

9. Open the metering valve about ¾ of a turn.

10. Check the flow rate in ounces per minute.

11. Adjust the metering valve, (open to increase flow or close to decrease flow) until the rate of 3.2 ounces per minute (or 1.5 gallons per hour) is attained. Allow several minutes between each adjustment before taking the rate sample.

12. When the metering valve is correctly adjusted, use the supplied allen wrench to lock in the adjustment and then shut down the engine.

13. Close the Shut-off valve on the Filter.

14. Reattach the metering valve to the Evaporator.

15. Attach a vent hose to the vapor escape valve on the top of the evaporator.

16. Open the Shut-off valve on the Filter.

17. Restart the engine and check for leaks. Fix any leaks as necessary.

Vapor EscapeValve

Metering Valve


Installation

Section 5 – Electrical Connections Notes: • Ensure the voltage of the truck matches the voltage of the system you are

installing.

• Use wire ties to secure all wires away from moving parts or extreme heat.

• Ensure the alternator has enough power to handle the additional load.

Connect the Power Source to the Evaporator 1. Remove the gauge cluster from the dash panel. See Figure 12.

Figure 12 – The Gauge Cluster

2. Locate the pigtail labeled “7”. See Figure 13.


Installation

Figure 13 – Pigtail #7

3. Connect the pin for the red wire lead to the wire supplied with the kit. NOTE: The black wire on the pigtail is not used for this installation. See Figure 14.

Figure 14 – Connecting the Power Lead


Installation

4. Route the power lead along the top of the dash panel to the passenger side of the vehicle to the point where the factory harness goes through the firewall.

5. Route the power lead through the same hole that factory harness passes through.

6. Route the power lead back toward the center of the vehicle to the Evaporator mounting bracket.

7. Connect the power lead to the red wire on the Evaporator.

8. Connect the black lead on the Evaporator to one of the mounting studs on the Evaporator mounting bracket.

9. Reattach the gauge cluster to the dash panel.

Apply Power to the Circuit

1. Locate the fuse panel. It is on the lower driver’s side of the dash panel.

2. Insert a 15 amp fuse in position 7 of the fuse panel.

3. Note on the fuse panel label that position 7 is being used for the OPS system.

Figure 15 – Electrical Connections

Documents

Oil Purification Systems, Inc. Purification Systems, Inc. Installation Instructions for Peterbilt Trucks Equipped with the Caterpillar C-13 Engine Document Part Number l-002